Ok you husky guys (and i don't mean that deraugitorily!) 2005 TE 450. Took the bike apart to send the motor to George. So just for fun I am putting it back together. I had the shock attached to the swingarm, and ran into considerable difficulty in putting it back on the bike. I ended up with putting the linkage back onto the shock mount first, followed by attaching the top of the spring to the frame. and finally the main bolt - pivot that goes through the engine. I had a bit of wiggling and use of a rubber persuasion tool to put it all back together - is this the way you guys do it? PS please forgive my ignorance - my other toy is a KTM - so I don't have a linkage! Carl Johansson Oh yah - subframe next - correct?
I'm just putting my '04 back together. The way I've done it is attach the pullrod / dogbone (the U-shaped bit) to the frame first and loosely fit the bellcrank (the vaguely triangular bit) to it. Then fit the bellcrank to the swingarm, The hardest bit was getting the washer on the end of the bolt through the hole in the swingarm - I ended up holding the nut in a long reach socket and sticking the washer to it with a dab of grease so I could screw it together in one hit. Torque everything up. Shock goes on last. My shock isn't back from the sussy tuner yet so I made a "hardtail" out of some steel scrap to hold everything together (it'll fall off the stand otherwise!) When you refit the subframe it may be a bit of a mare getting the intake boot back on the carb (unless you have four hands). Try loosely fitting either the top subframe bolt or the two bottom bolts and if possible enlist someone to swivel the subframe into position while you wriggle the boot onto the carb. Make sure your loom is routed properly while offering up the subframe.
It is straight forward, ttach the linkage to the swing arm, attach swing arm to the bike frame. Then attach the bottom of the shock to the linkage. No need to touch the sub frame. Then just put back the rear brake pedal, the rear brake line on the swing arm, the chain and rear wheel is the last bit.
